Académique Documents
Professionnel Documents
Culture Documents
Model
80HX
80HX+6
80HXER
3120271
November 19, 2003
ANSI
CALIFORNIAN PROPOSITION 65
BATTERY WARNING
Battery posts,
terminals and related
accessories contain
lead and lead compounds,
chemical known to the
State of California
to cause cancer and
reproductive harm.
WASH HANDS
AFTER HANDLING!
INTRODUCTION
SINCE THE MACHINE MANUFACTURER HAS NO DIRECT CON- • BEFORE MAKING ADJUSTMENTS, LUBRICATING OR
TROL OVER THE FIELD INSPECTION AND MAINTENANCE, PERFORMING ANY OTHER MAINTENANCE, SHUT
SAFETY IN THIS AREA RESPONSIBILITY OF THE OWNER/OPER- OFF ALL POWER CONTROLS.
ATOR. • BATTERY SHOULD ALWAYS BE DISCONNECTED-
DURING REPLACEMENT OF ELECTRICAL COMPO-
NENTS.
B HYDRAULIC SYSTEM SAFETY • KEEP ALL SUPPORT EQUIPMENT AND ATTACH-
It should be noted that the machines hydraulic systems MENTS STOWED IN THEIR PROPER PLACE.
operate at extremely high potentially dangerous pressures. • USE ONLY APPROVED, NONFLAMMABLE CLEANING
Every effort should be made to relieve any system pres- SOLVENTS.
sure prior to disconnecting or removing any portion of the
system.
REVISON LOG
TABLE OF CONTENTS
SUBJECT - SECTION, PARAGRAPH PAGE NO.
SECTION A - INTRODUCTION - MAINTENANCE SAFETY PRECAUTIONS
A General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
B Hydraulic System Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
C Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
SECTION 1 - SPECIFICATIONS
1.1 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
1.2 Component Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Engine - Ford LSG423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Deutz F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Wisconsin V465D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Cummins 4B 3.9C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Engine - Ford LRG-423 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Engine - Ford LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive Motor Displacement Machines Built Prior to Jan. 1992. . . . . . . . . . . . . . . . . . . . . . . . 1-2
Drive Motor Displacement Machines Built from Jan. 1992 to Present . . . . . . . . . . . . . . . . . 1-2
Drive Hub Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Steer System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Swing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Auxiliary Power Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic Filter - Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Hydraulic Filter - Inline (Racine Valve Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.3 Performance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-3
Travel Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Gradeability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Turning Radius (Outside) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Boom Speed (Telescope) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Boom Speed (Lift) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Swing Speed 360° . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Boom Elevation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Stowed Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Stowed Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Machine Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Maximum Tire Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Wheelbase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.4 Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
1.5 Lubrication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-4
Ford Engines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Deutz F4L912 Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Wisconsin V465D Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Cummins 4B 3.9C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Lubrication Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
1.6 Pressure Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Prior to Mid 1987. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
80 HX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
80HX w/Hydraulic Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
80HX w/Oscillating Axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
1.7 Major Components Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
1.8 Cylinder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-12
LIST OF FIGURES
FIGURE NO. TITLE PAGE NO.
1-1. Lubrication Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-5
1-2. Serial Number Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
1-3. Torque Chart - (In/Lb - Ft/Lb). (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
1-4. Torque Chart (Metric Conversion) - (For ASTM Fasteners) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-15
1-5. Torque Chart - (N, m) - (For Metric Class Fasteners). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-16
3-1. Torque Hub Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2
3-2. Drive Brake, Ausco - Machines Built Prior to October 1987. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9
3-3. Drive Brake, Mico - Machines Built Prior to October 1987 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-11
3-4. Drive Brake, Ausco - Machines Built Prior to 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-13
3-5. Drive Brake, Mico - Machines Built from 1992 to Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-15
3-6. Spring Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-16
3-7. Governor Adjustment, LRG-423 & LRG-425 with Adeco . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-17
3-8. Adeco Adjustment, LRG-423 & LRG-425 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-18
3-9. Precision Governor Adjustment - LRG-423 & LRG-425 (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . .3-19
3-10. Precision Governor Adjustment - LRG-423 & LRG-425 (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . .3-20
3-11. Adeco Actuator Adjustments - F4L912 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-21
3-12. Swing Bearing Bolt Feeler Gauge Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-34
3-13. Swing Bearing Tolerance Measuring Point. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-35
3-14. Swing Bearing Tolerance Boom Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-37
3-15. Swing Bearing Torquing Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-38
4-1. Boom Assembly (Sheet 1 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2
4-2. Boom Assembly (Sheet 2 of 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
4-3. Typical Boom Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-7
4-4. Telescope Cylinder Eccentric Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-10
4-5. Boom Tape Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-6. Capacity Indicator Dial . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
4-7. Belleville Washers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-11
5-1. Proportional Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2
5-2. Boom Positioning and Support - Cylinder Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5
5-3. Typical Hydraulic Cylinders (Sheet 1 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6
5-4. Typical Hydraulic Cylinders (Sheet 2 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7
5-5. Typical Hydraulic Cylinders (Sheet 3 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-8
5-6. Typical Hydraulic Cylinders (Sheet 4 of 4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-9
5-7. Cylinder Barrel Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-8. Cylinder Rod Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10
5-9. Poly-Pak Seal Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12
5-10. Telescope Cylinder Eccentric Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15
5-11. Racine Proportional Air Gap Adjustment, Machines Built Prior to Mid 1987 . . . . . . . . . . . . . . . . .5-16
5-12. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 1 of 2) . . . . . . . . . . . . . . .5-17
5-13. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 2 of 2) . . . . . . . . . . . . . . .5-18
LIST OF TABLES
TABLE NO. TITLE PAGE NO.
SECTION 1. SPECIFICATIONS
Engine - Ford LRG-423 2WD/2WS with fixed or oscillating front axle built
May 1988 to present - 24:1.
Oil Capacity - 5 quarts (4.7 L).
2WD/4WS with oscillating front axle built May 1988
Low RPM 1000 to present - 24:1.
Mid RPM 1800 4WD built May 1988 to present - 24:1.
High RPM 3000 2WD/4WS with fixed front axle/Vickers proportional
Horsepower - 66. valves - 73:1.
4WD with Vickers Proportional valves - 30.04:1.
Engine - Ford LRG-425
Oil Capacity - 4.5 quarts (4.25 L).
Steer System
Low RPM 1000 Toe-in, adjust for 1/4 in. (6.35 mm) overall.
Mid RPM 1800
Swing System
High RPM 3000
Horsepower - 75 Swing Motor - Displacement - 4.5 cu. in/Rev.
Drive System Swing Hub - Ratio - 69.50:1.
Pneumatic Tires - 15 x 19.5 NHS, 12 ply rating, Swing Brake - Automatic spring applied, hydrau-
65 PSI. (4.5 Bar). lically released disc brakes.
Foam-Filled Tires - 15 x 22.5 or 385/65R22.5 Hydraulic Pump
Air Pressure:
Firestone Tires - 95 PSI (6.5 Bar) Deutz and Wisconsin engines with Single Speed Drive
Goodyear Tires - 65 PSI (4.5 Bar) Motors (with Racine Valves).
Denman Tires - 70 PSI (4.8 Bar). First Section to Proportional Valve-Drive, Lift, Swing -
24 GPM (91 LPM).
Drive Motor Displacement Machines Built Prior
to Jan. 1992 Second Section to High Drive - 24 GPM (91 LPM).
Cessna - 5.04 in.3/rev. (4WD Same)
Third Section to Bang-Bang Valve Level, Telescope,
Vickers - 2.5/.98 in.3/rev.
Steer, Rotate - 9.5 GPM (36 LPM).
(4WD Same)
2 Speed Cessna - 2.48/1.103/rev. Clockwise Rotation.
Gear Reducer - Vickers Drive Motors only - 3.6:1.
Wisconsin Engines with 2 Speed Drive Motors and Deutz
Drive Motor Displacement Machines Built from Engines with Single Speed Drive Motors (with Racine
Valves).
Jan. 1992 to Present
First Section to Proportional Valve-Drive, Lift, Swing -
Rexroth - 2.8 in.3/rev.
19 GPM (72 LPM).
(4WD Same)
Drive Hub Ratios Second Section to High Drive - 19 GPM (72 LPM).
2WD with Racine proportional valves built prior to Third Section to Bang-Bang Valve Level, Telescope,
February 1988 - 42.5:1. Steer, Rotate - 9.5 GPM (36 LPM).
2WD with Racine proportional valves built February 1988
to present - 43:1. Clockwise Rotation.
2WD with Racine or Vickers proportional valves built prior
to October 1989 - 30.04:1.
Wheelbase
10 ft. (3 m)
Torque
Interval 1.5 LUBRICATION
Description
Hours
Ft. Lbs. Nm NOTE: The lubrication intervals in the following paragraphs
are equivalent to the following:
Turntable (prior to April, 1986) - -
5/8" Bolts - Wet 170 235
5/8" Bolts - Dry 220 304 50/600* 150 hours = 3 months
7/8" Bolts - Wet 460 636 300 hours = 6 months
7/8" Bolts - Dry
600 830
600 hours = 1 year
Turntable (April, 1986 to Present) - - 50/600* 1200 hours = 2 years
Wet 170 235
Dry 220 304
**Retorque after first 200 hours of operation and every 500 hours
thereafter.
Interval Hours
Number/Type
Components Capacity Lube 3 6 Comments
Lube Points Months Months
1 Year 2 Years
600 hrs 1200 hrs
150 hrs 300 hrs
1 Wheel Drive Hubs Level/Fill Plug 2.75 pt. (1/2 full) EPGL X Check level every 150 hours; change @
(SAE90 1200 hours
)
3 Slave Cylinder (Barrel) 1 Grease Fitting A/R MPG X Gain access through boom fly section.
9 Boom Chain Extension 1 Grease Fitting A/R MPG X Align access holes in mid and fly boom.
Sheave
1 Lift Cylinder (Barrel End) 1 Grease Fitting A/R MPG X Remote Access
1
Interval Hours
Number/Type
Components Capacity Lube 3 6 Comments
Lube Points 1 Year 2 Years
Months Months
600 hrs 1200 hrs
150 hrs 300 hrs
1 Engine Crankcase Fill Cap Refer to Engine Manual EO Check daily. Change in accordance with
6 engine manual.
1 Engine Oil Filter N/A N/A N/A Change in accordance with engine manual.
7
1 Engine Coolant Radiator Cap Refer to Engine Manual Refer to engine manual for coolant specifi-
8 cations. Check daily with engine cold.
1 Hydraulic Oil Fill Cap 56 gallons HO X Check daily. Change every 1200 hours.
9
2 Hydraulic Oil Return N/A N/A N/A Check filter gauges for element construc-
0 Filters tion daily. Replace as necessary.
2 Hydraulic Reservoir N/A N/A N/A X Replace filter element every 600 hours;
1 Suction Filter clean mesh as necessary.
2 Swing Drive Hub Fill Plug 17 oz. (1/2 Full) EPGL X Check oil level weekly; change every 600
7 (SAE90 hours
)
2 Swing Bearing and N/A A/R MPG X Apply by brush onto bearing and gear teeth
8 Pinion Gear Teeth
Interval Hours
Number/Type
Components Capacity Lube 3 6 Comments
Lube Points 1 Year 2 Years
Months Months
600 hrs 1200 hrs
150 hrs 300 hrs
Lubrication intervals are based on machine operation under normal conditions. For machines used in multi shift operations and/or exposed to hostile EO Engine Oil
environments or conditions, lubrication frequencies must be increased accordingly. EPGL Extreme Pressure Gear Lube
HO Hydraulic Fluid (Mobil #424 or equivalent)
MPG Multi-Purpose Grease
Single Viscosity Oils (SF, SF-SE, SF-CC, SF-CD). Single Viscosity Oils (MS, SD, SE).
When Outside Temp Use SAE When Outside Temp Use SAE
is Consistently Viscosity Number is Consistently Viscosity Number
-10° F - +60° F. *10W +15° F - 0° F. *10W
+10° F - + 90° F. 20W-20 +40° F - + 15° F. 20-20W
Above +32° F. 30 +120° F - + 40° F. 30
Above + 50° F. 40
Multi-Viscosity Oils (MS, SD, SE).
Multi-Viscosity Oils (SF, SF-SE, SF-CC, SF-CD).
When Outside Temp Use SAE
When Outside Temp Use SAE is Consistently Viscosity Number
is Consistently Viscosity Number Below Zero. *5W-20
Below +10° F. *5W-20
Below +60° F. 5W-30 NOTE: Crankcase oil should meet one of the following API
-10° F - +90° F. 10W-30 classification grades: SE/CC, SE/CD, SF/CC, SF/
Above -10° F. 10W-40 or CD.
10W-50
Above +20° F. 20W-40 or
Cummins 4B 3.9C
20W-50 Multiple Viscosity Oils (CE/SG).
* Not recommended for severe service - includ- When Outside Temp Use SAE
ing high RPM operation. is Consistently Viscosity Number
+70° F - 40° F. 5W-30
Deutz F4L912 Engine +70° F - -10° F. 10W-30
+120° F - + 10° F. 15W-40
Single Viscosity Oils (CD-SE, CD-SF).
When Outside Temp Use SAE
is Consistently Viscosity Number
-20° F - +25° F. *10W
+15° F - + 50° F. 20W-20
+40° F - + 85° F. 30
Above 75° F. 40
Multi-Viscosity Oils (CD-SE, CD-SF).
When Outside Temp Use SAE
is Consistently Viscosity Number
-40° F - +75° F. *5W-20
(Synthetic)
-5° F - +70° F. 10W-30
-5° F - +85° F. 10W-40
+15° F - +75° F. 15W-30
Above +15° F. 15W-40
* This viscosity can be used at colder temperatures only
with engine oil preheating.
Wheel 72 33
– JLG Lift –
13 0.1419 9050 75 55 68 85 12750 110 80 96 120 14190 110 120
1/2 0.5000
20 0.1599 10700 90 65 80 100 14400 120 90 108 130 15990 115 127
12 0.1820 11600 110 80 98 120 16400 150 110 139 165 18200 155 170
9/16 0.5625
18 0.2030 12950 120 90 109 135 18250 170 130 154 190 20300 165 182
11 0.2260 14400 150 110 135 165 20350 220 170 180 240 22600 210 231
5/8 0.6250
18 0.2560 16300 170 130 153 190 23000 240 180 204 265 25600 220 242
10 0.3340 21300 260 200 240 285 30100 380 280 301 420 33400 365 400
3/4 0.7500
16 0.3730 23800 300 220 268 330 33600 420 320 336 465 37300 400 440
9 0.4620 29400 430 320 386 475 41600 600 460 485 660 46200 585 645
7/8 0.8750
14 0.5090 32400 470 350 425 520 45800 660 500 534 725 50900 635 700
8 0.6060 38600 640 480 579 675 51500 900 680 687 990 60600 865 950
1 1.0000
12 0.6630 42200 700 530 633 735 59700 1000 740 796 1100 66300 915 1000
7 0.7630 42300 800 600 714 840 68700 1280 960 1030 1400 76300 1240 1365
3120271
VALUES FOR ZINC PLATED / YELLOW CHROMATE FASTENERS ONLY UNPLATED CAP SCREWS
SAE GRADE 5 BOLTS & SAE GRADE 8 BOLTS & GRADE 8 NUTS UNBRAKO 1960 SERIES
3120271
GRADE 2 NUTS & SOCKET HEAD CAP SCREWS SOCKET HEAD
TORQUE TORQUE TORQUE
TENSILE
THDS. BOLT CLAMP DRY OR LOCTITE CLAMP DRY OR LOCTITE CLAMP WITHOUT WITH
STRESS LOCTITE LOCTITE
SIZE PER DIA. LOAD LOCTITE LUB 242 OR LOAD LOCTITE LUB 242 OR LOAD LOC-WEL LOC-WEL
AREA 262 262
INCH 263 271 263 271 PATCH PATCH
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
40 0.00604 380 .8 .8 — — 540 1.4 1.0 — — — — —
4 0.1120
48 0.00661 420 1.0 .8 — — 600 1.5 1.0 — — — — —
32 0.00909 580 1.8 1.4 — — 820 2.6 2.0 — — — — —
6 0.1380
40 0.01015 610 2.0 1.6 — — 920 2.8 2.2 — — — — —
32 0.01400 900 3.4 2.4 — — 1260 4.6 3.4 — — — — —
8 0.1640
36 0.01474 940 3.4 2.6 — — 1320 5 3.6 — — — — —
24 0.01750 1120 5 3.6 — — 1580 7 5 — — — — —
10 0.1900
32 0.02000 1285 6 4 — — 1800 8 6 — — — — —
20 0.0318 2020 11 8 — 12 2860 16 12 — 18 3180 18 19
1/4 0.2500
28 0.0364 2320 14 10 — 15 3280 19 14 — 21 3640 19 20
IN SQ. IN. LB. N, m N, m N, m N, m LB. N, m N, m N, m N, m LB. N, m N, m
18 0.0524 3340 23 18 22 26 4720 34 24 30 41 5240 34 38
5/16 0.3125
24 0.0580 3700 26 19 23 28 5220 34 27 34 41 5800 37 41
16 0.0775 4940 41 31 38 47 7000 61 47 54 68 7750 61 68
3/8 0.3750
24 0.0878 5600 47 34 43 54 7900 68 47 61 75 8780 68 75
14 0.1063 6800 68 47 61 75 9550 95 75 85 108 10630 95 104
7/16 0.4375
20 0.1187 7550 75 54 68 81 10700 108 81 95 122 11870 102 111
13 0.1419 9050 102 75 92 115 12750 149 108 130 163 14190 149 163
1/2 0.5000
20 0.1599 10700 122 88 108 136 14400 163 122 146 183 15990 156 172
– JLG Lift –
12 0.1820 11600 149 108 133 163 16400 203 149 188 224 18200 210 230
9/16 0.5625
18 0.2030 12950 163 122 148 183 18250 230 176 209 258 20300 224 247
11 0.2260 14400 203 149 183 224 20350 298 230 244 325 22600 285 313
5/8 0.6250
18 0.2560 16300 230 176 207 258 23000 325 244 277 359 25600 298 328
10 0.3340 21300 353 271 325 386 30100 515 380 408 569 33400 495 542
3/4 0.7500
16 0.3730 23800 407 298 363 447 33600 569 434 456 630 37300 542 597
9 0.4620 29400 583 434 523 644 41600 813 624 658 895 46200 793 874
7/8 0.8750
14 0.5090 32400 637 475 576 705 45800 895 678 724 983 50900 861 949
8 0.6060 38600 868 651 785 915 51500 1220 922 931 1342 60600 1173 1288
1 1.0000
12 0.6630 42200 949 719 858 997 59700 1356 1003 1079 1491 66300 1241 1356
7 0.7630 42300 1085 813 968 1139 68700 1735 1302 1396 1898 76300 1681 1851
1-1/8 1.1250
12 0.8560 47500 1193 895 1087 1254 77000 1952 1464 1566 2135 85600 1871 2061
7 0.9690 53800 1518 1139 1368 1593 87200 2468 1844 1970 2712 96900 2373 2610
1-1/4 1.2500
12 1.0730 59600 1681 1247 1516 1763 96600 2712 2034 2183 2983 107300 2549 2807
1-15
SECTION 1 - SPECIFICATIONS
SECTION 1 - SPECIFICATIONS
SECTION 2. GENERAL
Primary Service
Type Frequency Reference
Responsibility Qualification
Pre-Start Inspection Prior to use each day; or User or Operator User or Operator Operator and Safety Manual
At each Operator change.
Pre-Delivery Prior to each sale, lease, or Owner, Dealer, or User Qualified JLG Service and Maintenance
Inspection rental delivery. Mechanic Manual and applicable JLG
inspection form.
Frequent Inspection In service for 3 months or 150 hours, which- Owner, Dealer, or User Qualified JLG Service and Maintenance
ever comes first; or Mechanic Manual and applicable JLG
Out of service for a period of more than 3 inspection form.
months; or
Purchased used.
Annual Machine Annually, no later than 13 months from the Owner, Dealer, or User Factory-Certified Service and Maintenance
Inspection date of the prior inspection. Service Technician Manual and applicable JLG
inspection form.
Preventative At intervals as specified in the Service and Owner, Dealer, or User Qualified JLG Service and Maintenance
Maintenance Maintenance Manual. Mechanic Manual
Component Disassembly and Reassembly 2. Unless specific torque requirements are given within
the text, standard torque values should be used on
When disassembling or reassembling a component, com-
heat-treated bolts, studs, and steel nuts, in accor-
plete the procedural steps in sequence. Do not partially
dance with recommended shop practices. (See
disassemble or assemble one part, then start on another.
Torque Chart Section 1.)
Always recheck your work to assure that nothing has been
overlooked. Do not make any adjustments, other than
Hydraulic Lines and Electrical Wiring
those recommended, without obtaining proper approval.
Clearly mark or tag hydraulic lines and electrical wiring, as
Pressure-Fit Parts well as their receptacles, when disconnecting or removing
them from the unit. This will assure that they are correctly
When assembling pressure-fit parts, use an anti-seize or reinstalled.
molybdenum disulfide base compound to lubricate the
mating surface. Hydraulic System
Bearings 1. Keep the system clean. If evidence of metal or rub-
ber particles are found in the hydraulic system, drain
1. When a bearing is removed, cover it to keep out dirt and flush the entire system.
and abrasives. Clean bearings in nonflammable
cleaning solvent and allow to drip dry. Compressed 2. Disassemble and reassemble parts on clean work
air can be used but do not spin the bearing. surface. Clean all metal parts with non-flammable
cleaning solvent. Lubricate components, as
2. Discard bearings if the races and balls (or rollers) required, to aid assembly.
are pitted, scored, or burned.
3. If bearing is found to be serviceable, apply a light Lubrication
coat of oil and wrap it in clean (waxed) paper. Do not Service applicable components with the amount, type,
unwrap reusable or new bearings until they are and grade of lubricant recommended in this manual, at
ready to install. the specified intervals. When recommended lubricants are
4. Lubricate new or used serviceable bearings before not available, consult your local supplier for an equivalent
installation. When pressing a bearing into a retainer that meets or exceeds the specifications listed.
or bore, apply pressure to the outer race. If the bear-
ing is to be installed on a shaft, apply pressure to the Battery
inner race. Clean battery, using a non-metallic brush and a solution of
baking soda and water. Rinse with clean water. After
Gaskets cleaning, thoroughly dry battery and coat terminals with
Check that holes in gaskets align with openings in the an anti corrosion compound.
mating parts. If it becomes necessary to hand-fabricate a
gasket, use gasket material or stock of equivalent material Lubrication and Servicing
and thickness. Be sure to cut holes in the right location, as Components and assemblies requiring lubrication and
blank gaskets can cause serious system damage. servicing are shown in the Lubrication Chart in Section 1.
INTERVAL
AREA
DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH YEARLY
BOOM
1. Platform 1,4
4. Footswitch 1,11
5. Controllers 1,11
6. Switches 1,11
13. Pins 8
14. Bushings 8
16. Chains 8 12
19. Sheaves 12
INTERVAL
AREA
DAILY WEEKLY MONTHLY 3 MONTH 6 MONTH YEARLY
TURNTABLE
2. Battery 3 5
3. Radiator 3 5
4. Air Cleaner 1 14
7. Engine Mount 1
IMPORTANT
WHEN REBUILDING TORQUE HUB, REMOVE AND REPLACE ALL
O-RINGS AND RETAINING RINGS.
7. Inspect all threaded components for damage includ- 8. Apply a coat of grease or petroleum jelly to cluster
ing stretching, thread deformation, or twisting. gear bore.
8. Inspect seal mounting area in hub for burrs or sharp
edges. Dress applicable surfaces or replace compo-
nents as necessary.
9. Inspect cover for cracks or other damage, and o-
ring sealing area for burrs or sharp edges. Dress
applicable surfaces or replace cover as necessary.
Repair
Cover Assembly.
1. Remove two bolts (25) securing disconnect cap (26) 9. Place sixteen needle rollers into cluster gear bore.
to cover (23) and remove cap.
2. Remove two bolts (25) securing cover cap (24) to
cover and remove cap.
3. Remove disconnect rod (27) from cap and remove
o-rings (28,29) from cover cap. Discard o-rings.
4. If necessary, remove pipe plug (30) from cover.
5. Clean and inspect parts in accordance with step 2.
Replace parts as necessary.
6. If removed, screw pipe into cover. 10. Place spacer into opposite side of cluster gear and
7. Slip o-ring (29) over cover cap and against face. against needle rollers.
8. Place o-ring (28) into cover cap internal groove. Dis-
connect rod may be used to push o-ring into
groove.
9. Place cover cap into cover with large hole located
over pipe plug. Secure cover cap to cover with two
bolts. Torque bolts to 70-80 in. lbs. (7.9-9.0 NM).
10. Place disconnect cap over cover cap with nipple fac-
ing out and secure with two bolts. Torque bolts to
70-80 in. lbs. (7.9-9.0 NM).
11. Turn cover over and push disconnect rod into cover 11. Place second set of sixteen needle rollers into clus-
cap. Rod will be held in place by friction from o-ring. ter gear.
Carrier Assembly.
1. Drive anti-roll pin (19) into planet (17) using a suit-
able punch.
2. Using a suitable press, press planet shaft from car-
rier 13. After planet shaft is removed, drive anti-roll
pin from shaft.
3. Remove cluster gear (18) and thrust washers (20,14)
from carriers.
12. Apply grease or petroleum jelly to tang side of two
4. Remove sixteen needle rollers (15) from cluster gear
thrust washers. Place thrust washers against bosses
bore.
in carrier with washer tang fitting into slot in carrier
5. Remove spacer (16) from cluster gear bore and outside diameter.
remove second set of sixteen needle rollers (15).
6. Repeat steps 1 thru 5 for remaining two cluster
gears.
7. Clean and inspect all parts in accordance with para-
graph b. Replace parts as necessary.
14. Line up cluster gear and thrust washers with hole in 5. Install retaining ring into input shaft groove to secure
carrier and slide planet shaft through. Ensure cham- spacers and spring to shaft.
fered side of hole in planet shaft is lined up with pin
hole in carrier. Assembly
4. Lower hub onto spindle (1) with large open end up.
12. Place thrust spacer (36) over input shaft (35) with 15. Place carrier assembly on a flat surface with large
counterbore side facing spindle. gears up and positioned as shown above. Find
punch marked tooth on each large gear and locate
at 12 o’clock (straight up) from each planet pin.
Marked tooth will be located just under carrier on
upper two gears.
16. With shoulder side of ring gear (21) facing down, 19. After inserting at least one shoulder bolt in the
place ring gear over (into mesh with) large gears. proper location, rotate the carrier. Check freedom of
Ensure punch marks remain in correct location dur- rotation and timing.
ing ring gear installation.
20. Install thrust washers and thrust bearing (39, 40) into
carrier counterbore.
17. While holding ring gear, input gear, and cluster
gears in mesh, place small side of cluster gears into
mesh with internal gear. On ring gear, locate hole
marked X over one of counterbored holes in hub.
18. Install input gear (37) into carrier, meshing with small
diameter cluster gears (18). Counterbore in bore of
input gear must be to outside of carrier assembly.
22. Place cover assembly over ring gear with oil level
check plug in cover located approximately 90
degrees from oil fill plug in hub.
23. Locate four shoulder bolts (42) 90 degrees apart into 25. Place coupling (43) into spindle and onto input
counterbored holes in hub marked in step (16). shaft.
Torque shoulder bolts to 23-27 ft. lbs. (31-36 NM). 26. Fill hub one-half full of EPGL 90 lubricant before
operation.
Disassembly
1. When shaft protruding downward, remove bolts (23)
alternately and evenly to reduce spring tension.
2. Remove power plate (20), o-ring (5), stationary discs
24. Install bolts (41) in remaining holes. Torque bolts to (13), springs (11), rotating discs (12), primary disc
23-27 ft. lbs. (31-36 NM). (10), pins (9), springs (6,7) and spring retainer (if so
equipped).
3. Further disassembly is not recommended unless
necessary for the replacement of specific parts.
4. If further disassembly is required, remove snap rings
(1,2), then remove shaft (8) from bearing (3) by
lightly tapping shaft with a plastic mallet.
5. Remove bearing from housing.
6. Remove piston (14) from the power plate (20) by
introducing low pressure air (15 PSI) into hydraulic
inlet. Make sure piston is directed away from opera-
tor. Remove o-rings (15,17) from the piston O.D. and
I.D. grooves. Back-up rings will be damaged and
should not be removed if replacement is not
planned.
7. Bleeder (19) can be removed and inspected to
assure spring loaded ball moves freely and is free of
contamination.
Figure 3-2. Drive Brake, Ausco - Machines Built Prior to October 1987
1. Insert new oil seal (24), dowel pins (22) and springs
END COVER IS UNDER SPRING TENSION OF APPROXIMATELY
(20,21) in housing (25).
1500 POUNDS (681 KG). THE FOUR CAPSCREWS SHOULD BE
LOOSENED EVENLY TO RELIEVE THIS FORCE. IF A HYDRAULIC 2. Install new bearing (23) on male end of shaft (14)
PRESS IS AVAILABLE (3000 LBS (1362 KG) MAXIMUM), THE and press until it shoulders on shaft.
COVER CAN BE HELD IN POSITION WHILE REMOVING THE CAP- 3. Insert shaft and bearing on housing (25) and press
SCREWS AND LOCKWASHERS. until bearing bottoms on shoulder in housing.
4. Position large diameter disc (19) in housing, with
2. Tap cover with a soft mallet in order to dislodge
tabs guided by dowel pins (22), until disc rests on
bearing (7) from cover.
springs (20,21).
3. Remove o-ring (6), square ring (5), pipe plug (3) and
bleeder screw (13) from end cover.
4. Remove piston (10) from end cover by inserting two DISC (15,19) AND FRICTION DISCS (17) SHOULD REMAIN DRY
1/4-20 UNC bolts into threaded holes in piston. By DURING INSTALLATION. NO OIL RESIDUE SHOULD BE ALLOWED
turning and pulling, piston can be removed from TO CONTAMINATE DISC SURFACES.
bore.
5. Remove o-ring (8), back-up ring (9), o-ring (11) and 5. Place friction disc (17) on shaft until it contacts bot-
back-up ring (12) from piston (24). tom disc (19). Insert one spring (16) on each dowel
6. Remove separators (18) from housing (25). pin (22).
Figure 3-3. Drive Brake, Mico - Machines Built Prior to October 1987
6. Add additional discs (15), friction discs (17), and NOTE: If available, a hydraulic press will simplify installation
springs (16) as required to complete assembly. of end cover on housing. Clamp cover in position
Alternate discs and friction discs during assembly. while tightening capscrews.
7. Insert separators (18) over spiral pins in housing. 12. To eliminate binding on bearings, press on inner ring
When properly installed, separators will contact top of bearing (7) until it shoulders on shaft. Restrain
of bottom disc. opposite end of shaft to avoid excessive thrust load-
8. Install o-ring (8), back-up ring (9), o-ring (11) and ing of bearing (24).
back-up ring (12) on piston 10. Insert piston into end
cover (4), being careful not to shear o-rings or back-
up rings. Inserting 1/4-20 UNC bolts in piston may IF HYDROSTATIC BENCH TESTING IS PERFORMED ON THE
simplify installation. BRAKE ASSEMBLY. RELEASE PRESSURE SHOULD NOT EXCEED
9. Install o-ring (6), bearing (7), square ring (5), pipe 2000 PSI (137.9 BAR) UNLESS TWO ADDITIONAL BOLTS ARE
plug (3) and bleeder screw (13) in end cover. USED FOR SUPPLEMENTAL CLAMPING.
10. Position end cover on housing, aligning dowel pins
with holes in cover, and push end cover until top fric- Bleeding
tion disc aligns with spline shaft.
1. Install brake and connect pressure lines.
11. Install capscrew (1) and lockwashers 2. Tighten
2. Bleed pressure release section of brake by pressur-
evenly to draw end cover to housing and bearing
izing side inlet port and allowing air to escape from
onto shaft. Torque capscrews to 55 ft. lbs. (75 NM).
top port. Pressure should not exceed 100 psi (6.9
Bar) during bleeding.
3. Apply sufficient pressure to release brake and check
for proper operation.
5. Using a shop press install seal (4) by pressing 5. Remove separators (10) from housing (7).
evenly around O.D. of seal. Use care to avoid cock- 6. Remove stack assembly, consisting of shaft (4),
ing. return plate (8), and friction discs (22), from housing
6. Install shaft (7) into housing. Support the inner race (7).
of bearing (3) when pressing shaft into bearing. 7. Remove dowel pins (17), springs (5,6) and spring
7. Install gasket 2. Align properly. After installing all the guide (16) from housing (7).
remaining internal components of the brake, install 8. Remove retaining ring (3) from housing (7).
bearing (18). Properly support the shaft when press-
ing the bearing onto shaft. 9. Remove shaft by pressing or using a soft mallet on
male end of shaft (4).
8. Install the power plate sub-assembly. Use a shop
press to evenly lower plate into position. There 10. Remove retaining ring (15) and bearing (2) from
should be no gap at the O.D. when the power plate shaft (4).
is properly seated against housing. If a shop press is 11. Press rotary oil seal (1) from housing (7).
not available, use the assembly bolts (22). Tighten
sequentially one turn at a time until the power plate Inspection
is properly seated. Torque to 50-60 ft. lbs. (68-81
NM). 1. Clean all parts thoroughly.
9. If replacement of pressure relief valve is necessary, 2. Closely inspect all parts for excessive wear, cracks,
install 1/2 to 3/4 turns beyond finger tight. and chips. Replace parts as necessary.
10. Bleed air from brake via bleeder screw. 3. Discard seals and o-rings.
4. Closely inspect bearings and bearing contact sur-
faces. Replace as necessary.
3.5 DRIVE BRAKE, MICO - MACHINES BUILT
FROM 1992 TO PRESENT NOTE: Bearings may be re-used if, after thorough inspec-
tion, they are found to be in good condition.
Disassembly
Assembly
1. Remove end cover (13) from housing (7) by remov-
ing capscrews (12). NOTE: Lubricate all seals and o-rings with clean hydraulic
oil prior to assembly.
Figure 3-5. Drive Brake, Mico - Machines Built from 1992 to Present
5. Insert dowel pins (17), spring guide (16) and springs 10. Install new o-ring (19), new back-up ring (18), new o-
(5,6) in housing (7) as shown in Figure 3-6., Spring ring (21) and new back-up ring (20) on piston (24).
Loading. Note order of o-rings and back-up rings. Insert pis-
ton (24) into end cover (13) being careful not to
shear o-rings or back-up rings.
11. Install new case seal (11) in housing (7) then install
bleeder screw (14) in end cover (13).
12. Position end cover (13) on housing (7) aligning
dowel pins (17) with holes in end cover.
13. Install capscrews (12) and tighten evenly to draw
end cover (13) to housing (7). Torque capscrews to
55 ft. lbs. (75 NM).
Adjustments
See Figure 3-7. and Figure 3-8.
1. From the basket (for idle) start the engine and allow
it to come up to operating temperature. Set the idle 3.7 THROTTLE CHECKS AND PRECISION
speed at 1000 RPM using the idle adjustment screw GOVERNOR ADJUSTMENTS, LSG-423 &
on the carburetor. Shut off the engine. LRG-425
2. Remove the cover on the Adeco actuator. With no NOTE: Never run the fuel tank dry. Diesel engines cannot be
function activated, the actuator should be fully restarted after running out of fuel until the fuel system
extended. Hold the governor arm in the idle position. has been air-vented or ‘bled’ of air. See the Deutz
Adjust slide pin (1) to contact the idle limit switch at Instruction Manual for procedure.
the output rod end of the actuator. Adjust the actua-
tor rod until you can hook it up to the governor arm. Checks
3. With the aid of an assistant, start the engine from the
1. Check that the anti-dieseling solenoid is operating. If
basket and allow it to come to operating tempera-
the solenoid is operating, an audible click at the car-
ture. Disconnect the proportional dump valve wire.
buretor should be heard when the ignition is
Activate the footswitch. Turn the high engine switch
switched on.
on. Hold the drive controller in the full drive position.
Adjust the slide pin (2) to contact high engine limit 2. Check the throttle linkage for smooth operation by
switch at 3000 RPM (2500 RPM for machines with rotating the throttle lever by hand to the full throttle
piston pump). Shut off all switches and controllers. position then slowly back to the idle position, feeling
Reconnect proportional dump valve wire. closely for sticking or binding. To accomplish this
the throttle rod must first be disconnected.
4. With the aid of an assistant, start the engine from the
basket and allow it to come to operating tempera-
Carburetor and Governor Adjustment
ture. Disconnect the bang-bang dump valve wire.
Activate the footswitch. Operate a bang-bang func- 1. With the aid of an assistant, start the engine at the
tion switch to increase RPM to low engine speed. platform console and allow it to come up to operat-
Using a small screwdriver set low engine speed at ing temperature with air cleaner installed. Adjust the
1800 RPM at the Adeco electronic module. carburetor idle screw until the engine idles at 1000
NOTE: Early machines are at idle until a function is acti- RPM. Shut down the engine.
vated. Later machines are at idle only at the platform NOTE: Steps 2 and 3 are preliminary settings.
without the footswitch activated. Therefore when set-
ting low engine speed on later machines it will not 2. On the controller (in ground control box) turn the
be necessary to disconnect the bang-bang dump “high engine.” (P1) adjusting screw 25-30 turns
valve wire or operate a bang-bang function. Just acti- CCW, then 10 turns CW.
vate the footswitch to get low engine speed. 3. On the controller (in ground control box) turn the
“gain” (P2) adjusting screw CCW to the stop, then
CW until the screw slot is vertical (approximately 1/4
turn).
4. On the controller (in ground control box) turn the
“droop” (P3) adjusting screw CCW to the stop, then
CW until the screw slot is vertical (approximately 1/4
turn). No further adjustment should be necessary to
“droop” (P3).
5. With the aid of an assistant at the platform console,
start the engine and allow it to come up to operating
temperature. Then have the assistant depress the
footswitch and place the engine speed switch to
HIGH ENGINE.
Mounting-Actuator Note that the angle between the carburetor arm and the
rod is 70 degrees with the engine at idle.This is very desir-
The Actuator may be mounted in any attitude - there is no
able! Note also that the Actuator arm travels equally on
preferred orientation
either side of a 90 degree angle with the rod. This angular
With no power applied, the actuator is spring loaded to arrangement will give the proper mechanical gain for
the minimum fuel position. The Actuator output shaft good stability and performance. It may be necessary to
rotates toward the maximum fuel position against this rotate the carburetor arm relative to the butterfly to
spring through electrical power from the controller. This achieve this. This can usually be done, and is usually
rotation is CW (clockwise) on one side of the Actuator, and worth the effort! Below are some workable installations,
CCW (counterclockwise) on the other. If necessary, with good linkages. Remember, the Actuator can be
reverse the Actuator on its mounting plate so that the turned 180 degrees on its mounting to "reverse" the
desired direction of rotation is on the desired side to spring-loaded direction. Also the Actuator can be
match the fuel system direction of travel. Mounted in any attitude.
Linkage
1/4 -28 threaded rod and low friction rod-end bearings are
recommended for linkage materials.
Keep the linkage as short and as straight as possible.
The linkage must not rub against the engine, brackets,
hoses, etc. The linkage must be free of friction and lost
motion or "slop"
The following sketch indicates the proper linkage geome-
try for most installations.
Examine the system for springs, such as carburetor return Power Distribution
springs. These should be removed. Some automotive car-
8 Pin Connector
buretors (as opposed to industrial carburetors) contain
internal springs for accelerator pumps, etc. These may Pin:
make good governing difficult, or even impossible. For a. 12 VDC from the make before break oil pressure
this and other reasons, industrial carburetors are pre- switch. This switch provides power to pin A
ferred. when the ignition is on and the engine is running
Move the linkage slowly through its travel, and look for (no oil pressure), or when the engine is off when
any binding or unexplained forces. Correct any before the engines running (has oil pressure).
going further. b. Ground.
Many “governing” problems are really caused by binding c. Tach signal from the engine ignition system.
of the butterfly and its shaft in the carburetor. This is d. Tach signal from the engine ignition system.
caused by loading due to vacuum under the butterfly and e. Control signal to operate the Actuator.
atmospheric pressure above when the engine is running.
f. Control signal to operate the Actuator.
These forces cannot be felt when the engine is not run-
ning. Therefore, start the engine while carefully controlling g. Removes ground from the start lock out relay
the speed by hand, and feel for binding or air load forces. when the engine is running above the start lock
Needle bearings on the butterfly shaft are available on out set point. A 20 turn pot is provided to adjust
many industrial carburetors to deal with this problem. Any this set point. (usually around 500 RPM)
tendency on the butterfly stick must be corrected. h. Removes ground from the overspeed relay if this
point is exceeded. A 20 turn pot is provided to
Mounting-Controller adjust this set point.(usually around 5000 RPM)
Select a reasonably cool, dry, and vibration free location. 4 Pin Connector
(5.) Incorrect Electrical Hook-up - If steps 1 - 4 above have If the above steps cannot be accomplished satisfactorily,
not revealed the problem, the governor may have been there is probably an actual Governor malfunction.
damaged, either in shipping or during hook-up and test.
a. Governor is unable to move fuel system freely
• Governor reacts, but can’t be set up to give proper per- (not enough Actuator force available). If Gover-
formance. nor doesn’t move fuel system to on far enough
to provide sufficient fuel but Governor arm
This kind of trouble usually falls into three main catego-
moves far enough when disconnected look for:
ries:
1. Linkage binding or misadjusted.
1. Actual Governor malfunction. 2. Low voltage at Governor during operation.
2. Governor installation problems and improper adjust- NOTE: *Measure the voltage as discussed previously and
ment. observe voltage during operation. If Governor fails to
3. Governor not tuned or adjusted for engine/applica- move full on and voltage dips over 1 volt, check for
tion. undersize wire (should be #16 minimum).
NOTE: Assure the engine is operating properly by running 3. Excessive force at Governor during engine running,
engine manually. The Governor will not control any particularly on carbureted engines.
poor running engine.
NOTE: *Carburetor butterfly valves are loaded by engine
(1.) Actual Governor Malfunction - The Governor was vacuum during running, which can add considerable
engine-tested for proper operation just prior to being force not present when engine isn’t running.
shipped. Unless damaged in shipment or by improper
handing, it should be serviceable. To check for proper NOTE: *Springs in the system; carburetor return springs,
operation proceed as follows: acceleration pump springs, etc., are not usually
needed and can cause governing problems.
a. Once again, disconnect fuel system linkage
from Governor output arm and control engine b. Governor is unstable at light-load or no-load.
manually. See “Linkage” for carburetor engines.
b. Start engine, hold at a low speed, Governor arm c. Governor experiences sudden, momentary
should move to full-fuel position. spikes toward max. at random intervals, then
c. Increase engine speed carefully. At some engine recovers.
speed, Governor arm should move to low-fuel 1. Look for loose wiring or momentary shorts in wiring.
position. Noise or occasionally missing speed signal.
d. By carefully varying engine speed, you should d. Speed seems to slowly wander (5-15 second
be able to cause the Governor arm to pause periods) around at speed, particularly at higher
momentarily near the middle of its travel. This loads. See item 2a. 3 concerning excessive on
engine speed is the speed for which the Gover- Governor.
nor is adjusted. If grossly incorrect, reset High
Engine Pot.
e. With the engine running at low speed, move the
Governor arm throughout its stroke by hand.
You should feel a constant smooth force in the
on direction. No binding or rubbing should be
felt within the Governor.
If steps 1a. thru 1e. can be accomplished as described,
the Governor is probably OK. It recognizes underspeed,
overspeed, onspeed and is not binding internally.
NOTE: This check is designed to replace the existing bear- Figure 3-12. Swing Bearing Bolt Feeler Gauge Check
ing bolt torque checks on JLG Lifts in service. This
check must be performed after the first 50 hours of
machine operation and every 600 hours of machine
operation thereafter. If during this check any bolts
are found to be missing or loose, replace missing or
loose bolts with new bolts and torque to the value
specified in the torque chart, after lubricating the bolt
threads with loctite #271. After replacing and
retorquing bolt or bolts recheck all existing bolts for
looseness.
5. Attach suitable overhead lifting equipment to the 3. Use suitable lifting equipment to carefully lower the
base of the turntable weldment. swing bearing into position on the frame. Ensure
6. Use a suitable tool to scribe a line on the inner race that the scribed line of the outer race of the bearing
of the swing bearing and on the underside of the aligns with the scribed mark on the frame. If a new
turntable. This will aid in aligning the bearing upon swing bearing is used, ensure that the filler plug fit-
installation. Remove the bolts, nuts and washers ting is at 90 degrees from the fore and aft centerline
which attach the turntable to the bearing inner race. of the frame.
Discard the nuts and bolts. 4. Ensure that all frame and bearing attachment holes
7. Use the lifting equipment to carefully lift the com- are aligned, and install four diametrically opposed
plete turntable assembly from the bearing. Ensure bolts or clamps to secure the bearing to the frame.
that no damage occurs to the turntable, bearing or Tighten the bolts or clamps evenly in a diametrically
frame-mounted components. opposed pattern to a torque of 20 ft. lbs. (3 kgm).
8. Carefully place the turntable on a suitably supported 5. Allow Devcon filler to cure at room temperature
trestle. (approximately 70 degrees F., 21 degrees C.) for 10
to 16 hours.
9. Use a suitable tool to scribe a line on the outer race
of the swing bearing and the frame. This line will aid 6. After the appropriate interval, release the clamps or
in aligning the bearing upon installation. Remove the remove the bolts. Use a suitable lifting device to
bolts and washers which attach the outer race of the carefully remove the bearing from the frame.
bearing to the frame. Discard the bolts. Use suitable 7. Carefully remove any excess filler from the frame
lifting equipment to remove the bearing from the mounting area, from the bearing attachment holes,
frame, move the bearing to a clean, suitably sup- and from between the gear teeth.
ported work area.
Installation.
ENSURE THE TURNTABLE IS ADEQUATELY SUPPORTED WHILE
NOTE: Steps 1 thru 13 apply only to machines built prior to
APPLYING DEVCON AND WHILE INSTALLING THE BEARING.
mid 1991. EXTREME CARE MUST BE TAKEN DURING THE FOLLOWING
NOTE: Manufacturing tolerances of frames and turntables STEPS TO AVOID SERIOUS OR FATAL INJURY TO PERSONNEL.
are inspected prior to the factory installation of swing
bearings to determine the need for use of Devcon 8. Apply a layer of Devcon (or equivalent) filler approxi-
filler. When servicing machine swing bearing, apply mately 0.125 inches (0.318 cm) thick to the under-
Devcon filler only to those machines having Devcon side of the bearing mounting area of the turntable
previously applied at the factory. If a new turntable or base plate.
frame is being installed, contact the manufacturer for
procedures to determine the need for Devcon appli-
cation.
18. Use suitable lifting equipment to carefully position Swing Bearing Torque Values
the turntable assembly above the machine frame. Prior to April, 1986.
19. Carefully lower the turntable onto the swing bearing,
1. Outer Race
ensuring that the turntable and bearing align as
noted in step 9 above. 5/8" Bolts - 170 ft. lbs. (235 NM) wet, 220 ft. lbs. (304
NM) dry.
7/8" Bolts - 460 ft. lbs. (636 NM) wet, 600 ft. lbs. (830
NM) dry.
IF COMPRESSED AIR OR ELECTRICALLY OPERATED IMPACT
WRENCH IS USED FOR TIGHTENING THE BEARING ATTACH- 2. Inner Race
MENT BOLTS, THE TORQUE SETTING ACCURACY OF THE TOOL 5/8" Bolts - 170 ft. lbs. (235 NM) wet, 220 ft. lbs. (304
SHOULD BE CHECKED PRIOR TO USE. NM) dry.
7/8" Bolts - 460 ft. lbs. (636 NM) wet, 600 ft. lbs. (830
20. Spray a light coat of Safety Solvent 13 to the new NM) dry.
bearing bolts. Then apply a light coating of Loctite
3. Swing Bearing Torquing Sequence, see Figure
#271 to the new bearing bolts, and install the bolts,
2-21.
washers and nuts through the turntable and inner
race of the bearing. April, 1986 to Present.
21. Following the Torque Sequence diagram shown in 1. Outer Race - 170 ft. lbs. (235 NM) wet, 220 ft. lbs.
Figure 3-15., torque the bolts to the values listed (304 NM) dry.
under Swing Bearing Torque Values. 2. Inner Race - 170 ft. lbs. (235 NM) wet, 220 ft. lbs.
22. Remove the lifting equipment. (304 NM) dry.
23. Install the rotary coupling retaining yoke, apply a 3. Swing Bearing Torquing Sequence, see Figure
light coating of Loctite Sealant #TL277-41 to the 2-21.
attaching bolts and secure the yoke to the rotary
coupling with the bolts and lockwasher.
24. Connect the hydraulic lines to the rotary coupling as RETORQUE THE INNER AND OUTER SWING BEARING BOLTS
tagged prior to removal. AFTER FIRST 200 HOURS OF OPERATION, AND EVERY 500
25. At the ground control station, use the boom lift con- HOURS THEREAFTER.
trol to lower the boom to the stowed position.
26. Using all applicable safety precautions, activate the
hydraulic system and functionally check the swing
system for proper and safe operation.
Disassembly
4.1 BOOM MAINTENANCE
Removal
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI-
1. Remove the platform from the boom assembly.
ATELY AFTER DISCONNECTING THE LINES TO AVOID ENTRY OF
2. Remove the slave leveling cylinder from the boom CONTAMINANTS INTO THE SYSTEM.
assembly.
1. Remove all hydraulic lines, electrical cables, carrier
NOTE: The boom assembly weighs approximately 4800 lbs.
tube, and power track from the right side of the
(2200 kg).
boom assembly.
3. Using suitable lifting equipment, adequately support 2. Remove control console from the platform.
the boom weight along the entire length of the
retracted boom. 3. Remove the platform from the fly boom assembly.
4. Remove the carrier tube and power track from the
right side of the boom assembly.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI- 5. Remove and disassemble the extension chain
ATELY AFTER DISCONNECTING LINES TO AVOID ENTRY OF attachment and adjustment assembly (mounted at
CONTAMINANTS INTO THE SYSTEM. aft of boom base section) as follows:
a. Remove the jam nut and nut which secures the
4. Tag and disconnect the hydraulic lines that run chain attachment clevis bolt to the chain adjust-
along the side of the boom. ment block.
5. Remove the hardware attaching the upper lift cylin- b. Remove the bolts and washers which secure the
der attach pin to the boom. extension chain attachment assembly to the
6. Using a slide hammer or similar tool, and taking care base boom section; remove the chain attach-
not to damage the pin, remove the pin from the ment assembly from the base boom section
boom. mounting point.
7. Using all applicable safety precautions, and only if c. Remove the cotter pins from the clevis pins.
necessary, operate the crane and fully retract the lift Remove the clevis pins and washers from the
cylinder. chain attachment clevis bolt; remove the chain
attachment clevis from the chain.
8. Shut down all machine systems.
6. Remove and disassemble the retraction chain
9. Tag and disconnect all wiring to the ground control attachment and adjustment assembly as follows:
box.
a. Remove the nuts and washers from the chain
10. Loosen and remove the hardware securing the attachment shield, and remove the shield from
boom pivot pin. the boom base section.
11. Ensuring that the boom is adequately supported b. Remove the jam nut and nut from the threaded
and using a suitable slide hammer, carefully remove end of the tension-adjusting clevis bolt. Remove
the pivot pin from the boom and turntable structure. the entire tension-adjusting assembly from the
Ensure the boom and turntable structure are not boom-mounted bracket.
damaged.
c. Remove the cotter pins from the clevis pins
12. Carefully lift the boom assembly clear of the turnta- which secure the retraction chains to the clevis
ble and lower to the ground or suitably supported bolt assembly.
work surface. d. Remove the cotter pins, nuts and bolts securing
the chain attach blocks to the clevis bolt assem-
bly. Remove the attach blocks.
e. Separate the top and bottom clevis bolt assem-
bly plates. Remove the clevis bolt from the bot-
tom plate.
7. Remove the snap rings from the pin which attaches 17. Using suitable lifting equipment, remove the fly sec-
the telescope cylinder rod end to the boom base tion from the mid section; place the fly section on a
section; use a brass drift to remove the pin. suitable trestle.
NOTE: Note and record the number and thickness of any 18. Remove the bolts which secure the wear pads to the
wear pad shims during wear pad removal. aft ends of the fly and mid sections; remove the wear
pads from the boom sections.
8. Remove bolts which secure the wear pads to the
inner forward surfaces of the boom base section. Inspection
Remove the wear pads from the top, sides and bot-
tom of the boom base section. 1. Inspect all sheaves (extend chains, retract chains
and telescope cylinder) for excessive groove wear,
9. Using suitable lifting equipment, carefully slide the
burrs or other damage. Replace the sheaves as nec-
assembled mid and fly sections from the base sec-
essary.
tion. Place the mid and fly sections on a suitable
trestle. 2. Inspect the extend chain and retract chain sheave
bearings for wear, scoring, or other damage, and for
10. Remove the setscrew which secures the sheave pin
ovality. Replace the bearings as necessary, ensuring
at the aft end of the mid section. Use a suitable
they are installed flush with the sheave surface.
brass drift to remove the pin. Remove the sheave
assembly. 3. Inspect the extend chain and retract chain sheave
pins for scoring, tapering, ovality and evidence of
11. Remove the bolts, washers and bar from the trun-
correct lubrication. Replace the pins as necessary.
nion pins which secure the cylinder base to the
boom mid section; use a suitable slide hammer to 4. Inspect the telescope cylinder sheave pin for taper-
remove the pins. ing, scoring, ovality and evidence of correct lubrica-
tion. Replace the pin as necessary.
5. Inspect the boom pivot pin for wear, scoring or other
WHEN REMOVING THE TELESCOPE CYLINDER FROM THE damage, and for tapering or ovality. Replace the pin
BOOM, IT MAY BE NECESSARY AT SOME POINT TO TURN THE as necessary.
CYLINDER SLIGHTLY IN ORD ER TO CLEAR ASSEM BLIES 6. Inspect the upper lift cylinder attach pin for tapering,
MOUNTED WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE ovality, scoring, wear, or other damage. Ensure the
THE CYLINDER SLOWLY FROM THE BOOM AS DAMAGE TO COM- pin surfaces are protected prior to installation.
PONENTS MAY RESULT FROM FORCIBLE IMPACT WITH THESE Replace pin as necessary.
ASSEMBLIES.
7. Inspect telescope cylinder trunnion attach pin for
tapering, ovality, scoring, wear, or other damage.
12. Pull the cylinder partially from the rear of the boom
Replace pin as necessary.
mid section; secure the cylinder with a suitable sling
and lifting device at approximately the center of 8. Inspect the extend chain attach clevis pins for wear,
gravity. scoring, or other damage. Replace the pins as nec-
essary.
13. Carefully remove the telescope cylinder and sheave
assembly. Place the cylinder on a suitable trestle. 9. Inspect the telescope cylinder rod attach pin for
scoring, wear, or other damage. Replace the pin as
14. Remove the bolts and washers from the sheave pin;
necessary.
remove the pin and the sheave assembly.
10. Inspect the inner diameter of the boom pivot bush-
NOTE: Note and record the number and thickness of any ing for scoring, distortion, wear, or other damage.
wear pad shims during wear pad removal. Replace the bushing as necessary.
15. Remove the bolts which secure the wear pads to the 11. Inspect all wear pads for excessive wear or damage.
inner surfaces of the boom mid section; remove the Replace the pads when worn to within 1/8 inch (3.2
wear pads from the top, sides and bottom of the mid mm) of insert.
section. 12. Inspect extend and retract chains and chain attach
16. Remove the bolts and lockwashers which secure the components for cracks, stretching, distortion, or
chain block weldment to the aft end of the fly sec- other damage. Replace components as necessary.
tion. Remove the cotter pins from the clevis pins 13. Inspect all threaded components for damage such
which secure the extension chain and retraction as stretching, thread deformation, or twisting.
chains to the block; remove the clevis pin, washers Replace as necessary.
and chains from the block.
14. Inspect structural units of the boom assembly for 11. Install wear pads into the forward portion of the mid
bending, cracking, separation of welds, or other section. Shim the boom, if necessary, for a total of 2/
damage. Replace boom sections as necessary. 10 inch (.20) clearance.
12. Align the attach points of the retraction chains with
Assembly those of the chain attachment block, located at the
aft end of the fly section. Install the clevis pins and
NOTE: When installing fly section wear pads, install the washers through the attaching holes of the chains
same number and thickness of shims as were and block; secure the clevis pins by installing new
removed during disassembly. cotter pins.
1. Measure the inside dimensions of the base and mid 13. Properly position the retraction chain sheave assem-
sections to determine the number of shims required blies at the aft end of the mid section; ensure all
for proper lift. sheave-to-mounting block attachment holes align.
2. Install side wear pads to the aft end of the fly sec- Install the sheave pin and secure by installing the
tion; shim evenly to the measurements of the inside setscrews. Position the retraction chains onto the
of the mid section. sheaves.
3. Install the side wear pads to the aft end of the mid 14. Align the telescope cylinder base-to-sheave attach-
section; shim evenly to the measurement of the ment points. Install the sheave pin through the cylin-
inside of the base section. der base and sheave assembly; secure the pin with
bolt and washer.
4. Shim the insides of the boom sections for a total of
1/16 inch (.062) clearance (if the action is centered, 15. Secure the sling and lifting device at the telescope
there will be 1/32 clearance on each side). cylinder’s approximate center of gravity, and lift the
cylinder to the aft end of the boom assembly.
5. Slide the fly section into the mid section a distance
of approximately one foot; take the measurement of
the inside of the mid section top wear pad clearance
and fabricate shim packs. WHEN INSERTING THE TELESCOPE CYLINDER INTO THE BOOM,
IT MAY BE NECESSARY AT SOME POINT TO TURN THE CYLIN-
6. Remove the fly section from the mid section and
DER SLIGHTLY IN ORDER TO CLEAR ASSEMBLIES MOUNTED
install two top wear pads and a shim pack. Shim the
WITHIN THE BOOM. CARE MUST BE TAKEN TO MOVE THE CYL-
top of the fly section for a total of 1/16 inch (.062)
INDER SLOWLY INTO POSITION AS DAMAGE TO COMPONENTS
clearance.
MAY RESULT FROM FORCIBLE IMPACT WITH THESE ASSEM-
7. Slide the mid section into the base section a dis- BLIES.
tance of approximately one foot; take the measure-
ment of the top wear pad clearance and fabricate 16. Position the free end of the extension chain around
shim packs. and over the sheave. Slowly slide the cylinder into
8. Remove the mid section from the base section and the boom while maintaining tension on the chain.
install two top wear pads and a shim pack. Shim the (This will keep the chain properly seated in the
top of the mid section for a total of 1/16 inch (.062) sheave groove throughout installation).
clearance. 17. Align the cylinder base-end attachment holes with
9. Attach the extension chain to the appropriate clev- the boom mid section attachment holes; install the
ised attachment point of the chain block weldment trunnion pins and secure the pins by installing bars,
by installing the clevis pin and washer through the washers and bolts.
attach holes; secure the clevis pin with a new cotter 18. Slide the mid section into the base section. Allow the
pin. Place the chain block weldment in position at retraction chains to trail between the bottom sur-
the aft end of the fly section; secure the weldment by faces of boom sections. Ensure that no twists exist
installing the bolts and washers. in the chains. Shim the top of the mid section for a
total of 1/16 inch (.062) clearance.
19. Install wear pads into the forward portion of the base
WHEN ASSEMBLING BOOM SECTIONS, ENSURE THE BOOM section. Shim the boom, if necessary, for a total of 2/
SLIDING TRAJECTORIES HAVE BEEN CLEARED OF CHAINS, 10 inch (.20) clearance.
TOOLS, AND OTHER OBSTRUCTIONS. 20. Assemble the extension chain attachment and
adjustment assembly (mounted at aft of boom base
10. Slide the fly section into the mid section. Shim the section) as follows:
boom, if necessary, for a total of 1/16 inch (.062)
clearance. a. Align the attaching holes of the chain attach-
ment clevis bolt with those of the extension
chain end; install the clevis pin through the proper hose and cable ends through the fly sec-
attaching holes. Install the washer and cotter pin tion carrier tube and into the hole in the boom fly
which secures the clevis pin through the chain section. Properly align the power track end with
attachment assembly. the attachment point of the fly section carrier
21. Align the cylinder rod-end attachment point with tube; install the bolts, washers, lock washers
those of the boom base section. If necessary, use an and nuts which secure the power track to the
auxiliary hydraulic power source to extend and carrier tube.
retract the cylinder rod for alignment. Install the c. Carefully feed the remaining hose and cable
cross pin through the base boom section and cylin- ends aft through the base section carrier tube.
der rod. Install the snap rings onto the cross pin. Properly align the remaining power track end
with the attachment point of the base section
22. Align the chain attachment assembly holes with the
carrier tube; install the bolts, washers, lockwash-
threaded mounting holes at the aft end of the boom
ers and nuts which secure the power track to
by installing the bolts and washers.
carrier tube.
23. Insert the threaded end of the chain attachment cle-
d. Ensure all hoses and cables are properly routed
vis bolt through the large hole of the chain attach-
through the carrier tube and power track.
ment weldment. Loosely install the jam nut and nut
Tighten or install all clamping or securing appa-
onto the threaded end of clevis bolt.
ratus to the hoses or cables, as necessary.
24. Assemble and install the retraction chain attachment
and adjustment assembly as follows: Installation
a. Place the clevis bolt on the bottom plate and
1. Using suitable lifting equipment, position the assem-
place the top plate onto the clevis assembly.
bled boom on turntable so that boom pivot holes in
Secure the clevis bolt with clevis pins, washers
both boom and turntable are aligned.
and new cotter pins.
b. Insert chain attach blocks between the clevis 2. Insert boom pivot pin, ensuring that locating slots in
plates ensuring the attachment points are prop- pin are aligned with setscrew locating holes in pin
erly aligned. Secure the block in position with bushings.
bolts, nuts and new cotter pins. 3. If necessary, gently tap the pin into position with a
c. Align the retraction chains with the clevis attach soft headed mallet. Secure the pin with setscrews.
blocks; secure the chains with clevis pins, wash- 4. Connect all wiring to the ground control box.
ers and new cotter pins.
5. Using all applicable safety precautions, operate lift-
d. Position the bolt end of the extension-adjust- ing equipment in order to position the boom lift cyl-
ment clevis into the boom mounted bracket. inder so the holes in the cylinder rod end and boom
Secure the chain-adjusting assembly by install- structure are aligned. Insert the lift cylinder pin.
ing the jam nut and nut.
6. If necessary, gently tap the pin into position with a
e. Position the chain adjustment shield over the soft headed mallet, ensuring the pin plate holes are
chain adjustment assembly; secure the shield aligned with the attach holes in the boom structure.
by installing the bolts and washers. Install the pin attaching bolts, washers and lock-
25. Adjust the retract and extend chains to the proper washers.
torque. (See adjusting procedures of Section 4.2). 7. Shut down all machine systems.
26. Install the hydraulic hoses, electrical cables, and the 8. Connect the hydraulic lines running alongside of
harnessing power track components as follows: boom.
a. Properly position the fly section carrier tube with 9. Using all applicable safety precautions, operate the
carrier tube bracket installed at the side of the machine systems and raise and extend the boom
boom. Align the attachment holes the forward fully, noting the performance of the extension cycle.
end of the carrier tube with those of the fly sec- If chattering is apparent, the extend chain system
tion mounting plate. Secure the carrier tube by requires adjustment.
installing the bolts, washers, lock washers and
nuts. Align the support bracket with attachment 10. Retract and lower the boom, noting the performance
holes in the mid boom and secure with bolts and of the retraction cycle. If chattering is apparent, the
washers. retract chain system requires adjustment.
b. Properly position the assembled hoses, electri- 11. Shut down all machine systems.
cal cable, and the harnessing power track onto 12. Adjust the extend and retract chain systems as
the base section carrier tube. Carefully feed the required and secure the adjustment locknuts.
13. As necessary, lubricate all points requiring lubrica- JLG Industries, Inc. requires a complete boom disassem-
tion. bly, per instructions outlined in Section 4.1, Boom Mainte-
nance, every two years. All boom chains and related
components (i.e., sheaves, pins, sprockets, wear pads,
4.2 BOOM CHAINS etc.) must also be inspected and replaced (as necessary)
during this disassembly.
(See Figure 4-3.)
An immediate disassembly of the boom assembly and
Adjusting Procedures inspection of the boom chains and related components is
required if any of the following conditions occur:
1. After the machine is exposed to hostile environ-
ments or conditions (i.e. extreme cold, dust, sand,
ENSURE THE MACHINE IS ON A FIRM AND LEVEL SURFACE.
blasting grit, salt, chemicals, etc.), which could
adversely affect boom operation.
1. Fully retract the boom in the horizontal position (±
5°) with no load in the platform. 2. Erratic boom operation or unusual noise exists. See
the Troubleshooting section in this Service Manual.
2. Extend the platform approximately 3 ft. (1 meter).
3. Chain adjustment is required more often than speci-
3. Torque the boom retract chain adjuster to 50 ft. lbs.
fied in the Preventive Maintenance and Inspection
(69 NM), then torque the boom extend chain
Schedule in this Service Manual or links need to be
adjuster to 50 ft. lbs. (69 NM).
removed (chain shortened) to make the proper
4. Retract the platform approximately 1 ft. (0.3 m). adjustment.
5. Check the boom extend chain adjusters (50 ft. lbs. 4. The machine is idle for an extended period (6
{69 NM} required). months or longer.)
6. Retract the platform approximately 1 ft. (0.3 m) once 5. The boom is overloaded or sustained a shock load.
again.
7. Recheck the extend chain adjusters (50 ft. lbs. {69
NM} required).
8. Extend the platform approximately 1 ft. (0.3 m).
Check for proper operation of boom.
9. Recheck the retract chain adjuster torque. (50 ft. lbs.
{69 NM} required).
10. Fully extend and retract the boom and check for
proper operation.
10. Tight Joints: All joints in the roller chain should flex
freely. On roller chain, tight joints are usually caused
by rust/corrosion, or the inside plates “walking” off
7. Lubrication: One of the most important but often
the bushing. Limber up rusty/corroded chains (after
overlooked factors is adequate lubrication. In addi-
inspecting care fully) with a heavy application of oil
tion to reducing internal friction, maintaining a film of
(preferably a hot oil dip). Tap inside “walking” plates
oil on all chain surfaces will inhibit rusting and corro-
inward; if “walking” persists, replace the chain. This
sion. This is important as corrosion of highly
type of problem is accelerated by poor lubrication
stressed, hardened steel chain components can
maintenance practice, and most tight joint chains
cause a major reduction in the load capacity of leaf
have been operated with little or no lubrication. Tight
chain and result in link plate cracking.
joints on leaf chain are generally caused by:
11. Bent pins or plates.
12. Rusty joints.
13. Peened plate edges.
Oil rusty chains, and replace chains with bent or peened In the chain, static stress is present at the aperture
chain components. Keep chains lubricated. due to the press fit pin. No cycle motion is required
and the plates can crack during idle periods. The
TIGHT JOINTS reactions of many chemical agents (such as battery
acid fumes) with hardened metals liberate hydrogen
which attacks and weakens the metal grain struc-
ture.
16. Chain Anchors, Sheaves and Pins: An inspection
14. Protruding or Turned Pins: Chains operating with of the chain must include a close examination of
inadequate lube generate tremendous friction chain anchors, sheaves and pins. Check chain
between the pin and plates (pin and bushing on anchors for wear breakage and misalignment.
roller chain). In extreme cases, this frictional torque Anchors with worn or broken fingers should be
can actually turn the pins in the outside press-fit replaced. They should also be adjusted to eliminate
plates. Inspect for turned pins, which can be easily twisting the chain for an even load distribution.
spotted as the “V” flats on the pin heads are no Sheaves should be inspected for worn flanges, which
longer in line. Replace all chains showing evidence would indicate misalignment, and wear on the outside
of turned or protruding pins. Keep chains lubricated. diameter of the sheave. A worn sheave can mean several
15. Stress Corrosion Cracking: The outside link problems, as follows:
plates, which are heavily press-fitted to the pins, are 1. Chains too tight.
particularly susceptible to stress corrosion cracking.
Like fatigue cracks, these initiate at the point of high- 2. Sheave bearings/pin bad.
est stress (aperture) but tend to extend in an arc-like 3. Bent/misaligned chains.
path, often parallel to the rolling grain of the material. .
0.50 in. (1.27 cm) 14 in. (36 cm) or 0.42 in. (1.07 cm)
pitch 28 pitches
Also, more then one crack can often appear on a
link plate. In addition to rusting, this condition can 1.00 in. (2.54 cm) 14 in. (36 cm) or 0.42 in. (1.07 cm)
be caused by exposure to an acidic or caustic pitch 14 pitches
medium or atmosphere. Stress corrosion is an envi-
1.75 in. (4.45 cm) 14 in. (36 cm) or 8 0.42 in. (1.07 cm)
ronmentally assisted failure. Two conditions must be
pitch pitches
present; corrosive agent and static stress.
ARC-LIKE CRACKED PLATES 2.00 in. (5.08 cm) 14 in. (36 cm) or 7 0.42 in. (1.07 cm)
(STRESS CORROSION)
pitch pitches
OEM
4.4 TELESCOPE CYLINDER ECCENTRIC
Refer to separate publication (3120344) for description
BUSHING troubleshooting, wiring and replacement parts.
Installation Procedure
1. Clean and dry fly boom top surface before installing
the tape.
2. Install tape on center of fly boom to dimensions
shown in table.
SECTION 5. HYDRAULICS
Cylinders Without Counterbalance Valves OPERATE ALL FUNCTIONS FROM THE GROUND CONTROLS.
(Steer Cylinder and Master Cylinder)
1. Using all applicable safety precautions, activate the
1. Using all applicable safety precautions, activate the hydraulic system.
engine and fully extend the cylinder to be checked.
Shut down the engine.
2. Carefully disconnect the hydraulic hose from the WHEN WORKING ON THE LIFT CYLINDER, RAISE THE BOOM TO
retract port of the cylinder. There will be initial weep- HORIZONTAL AND PLACE A BOOM PROP APPROXIMATELY 1
ing of hydraulic fluid which can be caught in a suit- INCH (2.50 CM) BELOW THE BOOM. DO NOT WORK ON THE CYL-
able container. After the initial discharge there INDER WITHOUT A SUITABLE PROP IN PLACE. REFER TO FIG-
should be no further leakage from the retract port. URE 5-2.
3. Activate the engine and extend the cylinder.
2. After completing the above, shut down the hydraulic
4. If cylinder retract port leakage is less than 6-8 drops system and allow the machine to sit for 10-15 min-
per minute, carefully reconnect the hose to the port utes. Turn the IGNITION SWITCH to ON, move the
and retract the cylinder. If leakage continues at a control switch or lever for the applicable cylinder in
rate of 6-8 drops per minute or more, cylinder each direction, then turn the IGNITION SWITCH to
repairs must be made. OFF. This is done to relieve pressure in the hydraulic
5. With the cylinder fully retracted, shut down the lines. Carefully remove the hydraulic hoses from the
engine and carefully disconnect the hydraulic hose appropriate cylinder port block.
from the cylinder extend port. 3. There will be initial weeping of hydraulic fluid, which
can be caught in a suitable container. After the initial
6. Activate the engine and retract the cylinder. Check discharge, there should not be any further leakage
the extend port for leakage. from the ports. If leakage continues at a rate of 6-8
drops per minute or more, the following cylinder
7. If the extend port leakage is less than 6-8 drops per repairs must be made. If the retract port is leaking,
minute, carefully reconnect the hose to the extend the piston seals are defective and must be replaced.
port, then activate the cylinder through one com- If the extend port is leaking, the counterbalance
plete cycle and check for leaks. If leakage continues valve is defective and must be replaced.
at a rate of 6-8 drops per minute or more, cylinder
repairs must be made. 4. If no repairs are necessary or when repairs have
been made, carefully reconnect the hydraulic hoses
to the appropriate ports.
5. If used, remove the boom prop from beneath the
boom, activate the hydraulic system and run the cyl-
inder through one complete cycle to check for leaks.
NOTE: See Figure 5-3., Figure 5-4., Figure 5-5., and Figure
OPERATE ALL FUNCTIONS FROM THE GROUND CONTROL STA- 5-6. for the breakdown of typical hydraulic cylinders
TION ONLY. used on this machine.
1. Using all applicable safety precautions, activate the
Disassembly
hydraulic system.
2. When working on the platform slave level cylinder,
stroke the platform slave level cylinder forward until IMPORTANT
the platform sits at a 45° angle. DISASSEMBLY OF THE CYLINDER SHOULD BE PERFORMED ON
A CLEAN WORK SURFACE IN A DIRT FREE WORK AREA.
3. Shut down the hydraulic system and allow the
machine to sit for 10-15 minutes. If the machine is 1. Connect a suitable auxiliary hydraulic power source
equipped with bang-bang or proportional control to the cylinder port block fitting.
valves, turn the IGNITION SWITCH to ON, move the
control switch or lever for the applicable cylinder in
each direction, then turn the IGNITION SWITCH to DO NOT FULLY EXTEND THE CYLINDER TO THE END OF THE
OFF. If the machine is equipped with hydraulic con- STROKE. RETRACT THE CYLINDER SLIGHTLY TO AVOID TRAP-
trol valves, move the control lever for the applicable PING PRESSURE.
cylinder in each direction. This is done to relieve
pressure in the hydraulic lines. Carefully remove the 2. Operate the hydraulic power source and extend the
hydraulic hoses from the appropriate cylinder port cylinder. Shut down and disconnect the power
block. source. Adequately support the cylinder rod, if appli-
4. There will be initial weeping of hydraulic fluid which cable.
can be caught in a suitable container. After the initial
discharge, there should not be any further leakage
from the ports. If leakage continues at a rate of 6-8 ON CYLINDERS WITH DOUBLE HOLDING VALVES, BEFORE
drops per minute or more, the counterbalance valve REMOVING HOLDING VALVES, CRACK THE BLEEDERS TO
is defective and must be replaced. RELEASE PRESSURE.
5. To check the piston seals, carefully remove the
counterbalance valve from the retract port. After ini- 3. If applicable, remove the cartridge-type holding
tial discharge there should not be any further leak- valve and fittings from the cylinder port block. Dis-
age from the ports. If leakage occurs at a rate of 6-8 card the o-rings.
drops per minute or more, the piston seals are
defective and must be replaced.
6. If no repairs are necessary or when repairs have
been made, replace the counterbalance valve and
carefully connect the hydraulic hoses to the cylinder
port block.
7. If used, remove the lifting device from the upright or
remove the prop from below the boom, activate the
hydraulic system and run the cylinder through one
complete cycle to check for leaks.
Cleaning and Inspection 13. If applicable, inspect the seal grooves in the thread
ring for burrs and sharp edges. Dress applicable
1. Clean all parts thoroughly in an approved cleaning surfaces as necessary.
solvent.
14. If applicable, inspect the rod and barrel bushings for
2. Inspect the cylinder rod for scoring, tapering, ovality, signs of correct lubrication and excessive wear.
or other damage. If necessary, dress the rod with Replace as necessary.
Scotch Brite or an equivalent. Replace the rod if nec-
15. Inspect the travel limiting collar or spacer for burrs
essary.
and sharp edges. If necessary, dress the inside
3. Inspect the threaded portion of the rod for excessive diameter surface with Scotch Brite or equivalent.
damage. Dress the threads as necessary.
16. If applicable, inspect the port block fittings and hold-
4. Inspect the inner surface of the cylinder barrel tube ing valve. Replace as necessary.
for scoring or other damage. Check the inside diam-
17. On the telescope cylinder only, inspect the cylinder
eter for tapering or ovality. Replace if necessary.
rod support block and wear ring inside diameter for
5. Inspect the threaded portion of barrel for damage. scoring or other damage. Repair or replace as nec-
Dress the threads as necessary. essary.
6. Inspect the piston surface for damage and scoring 18. Inspect the oil ports for blockage or the presence of
and for distortion. Dress the piston surface or dirt or other foreign material. Repair as necessary.
replace the piston as necessary.
19. If applicable, inspect piston rings for cracks or other
7. Inspect the seal and o-ring grooves in the piston for damage. Replace as necessary.
burrs and sharp edges. Dress applicable surfaces
as necessary. NOTE: Steps 20 thru 23 apply to the Telescope Cylinder
only.
8. Inspect the cylinder head inside diameter for scoring
or other damage and for ovality and tapering. 20. Inspect the chain sheave bushings for scoring,
Replace as necessary. tapering, ovality and for excessive wear and evi-
9. Inspect the seal and o-ring grooves in the cylinder dence of correct lubrication. Replace the bushing as
head for burrs and sharp edges. Dress applicable necessary.
surfaces as necessary. 21. Inspect the sheave chain groove for damage.
10. If applicable, inspect the cylinder head retainer or Replace the sheave assembly as necessary.
end cap for surface or thread damage. Repair or 22. Inspect the sheave attach pin for scoring or other
replace as necessary. damage and for evidence of correct lubrication.
11. Inspect the cylinder head outside diameter for scor- Dress the pin surface with Scotch Brite or equivalent
ing or other damage and ovality and tapering. or replace the pin as necessary.
Replace as necessary. 23. Inspect the sheave pin lubrication drilling and fitting
12. If applicable, inspect the thread ring for scoring or for blockage or the presence of dirt or other foreign
other damage. Dress the threads or applicable sur- material. Repair as necessary.
faces as necessary.
Assembly 8. Push the piston onto the rod until it abuts the spacer
end and install the attaching nut.
NOTE: Prior to cylinder assembly, ensure that the proper
cylinder seal kit is used. See your JLG Parts Manual.
WHEN REBUILDING THE LIFT, SLAVE LEVEL, TELESCOPE,
Apply a light film of hydraulic oil to all components
STEER, AND EXTEND-A-REACH SLAVE AND LIFT CYLINDERS,
prior to assembly.
APPLY LOCTITE #242 TO PISTON NUT, THEN TIGHTEN BOTH
SECURELY. (SEE TABLE 5-1 FOR TORQUE SPECIFICATIONS).
IMPORTANT
WHEN INSTALLING ‘POLY-PAK’ PISTON SEALS, ENSURE THE NOTE: These cylinders use self-locking knurled cup point
SEALS ARE INSTALLED PROPERLY. REFER TO FIGURE 2-3 FOR setscrews which should be discarded and replaced
CORRECT SEAL ORIENTATION. IMPROPER SEAL INSTALLATION whenever they are removed.
COULD RESULT IN CYLINDER LEAKAGE AND IMPROPER CYLIN-
DER OPERATION. After torquing the piston nut spot drill cylinder rod for
setscrews.
IF THE CYLINDER IS TO BE TESTED PRIOR TO INSTALLATION ON Steer Cylinder 80 ft.lbs. 100 in.lbs.
(109 Nm) (12 Nm)
THE MACHINE, EXTREME CARE SHOULD BE USED TO INSURE
THAT THE OUTER END OF THE ROD IS SUPPORTED. USE Steer Cylinder 275-330 ft.lbs. N/A
EITHER A TRAVELING OVERHEAD HOIST, FORKLIFT, OR OTHER (Oscillating Axle) (380-456 Nm)
MEANS TO SUPPORT THE OVERHANGING WEIGHT OF THE
EXTENDING ROD. Lockout Cylinder N/A N/A
NOTE: Steps 20 thru 23 apply to the Boom Telescope Cylin- Telescope Cylinder 600 ft.lbs. 100 in.lbs.
ders. (814 Nm) (12 Nm)
20. Elevate the barrel end of the cylinder to a work Axle Extension Cyl. 50 ft.lbs. 100 in.lbs.
bench or other suitable device. (7 Nm) (12 Nm)
21. Plug the retract port and supply hydraulic power to Axle Extension Cyl. 100 ft.lbs. 100 in.lbs.
the extend port. (Oscillating Axle) (138 Nm) (12 Nm)
22. Open the bleeder port plug (TP) venting all trapped
air to atmosphere. Retighten the bleeder port plug. Axle Lift Cylinder 400 ft.lbs. 100 in.lbs.
(553 Nm) (12 Nm)
Disconnect the hydraulic power source and remove
plug from retract port. Tie-Rod Cylinder 150-180 ft.lbs. N/A
23. An alternative to steps (20) through (23) is to posi- (Oscillating Axle) (210-250 Nm)
tion the barrel horizontally in a suitable holding
device, attach a hydraulic power source to both Extend-A-Reach
extend and retract ports, while supporting the cylin-
Lift Cylinder 200 ft.lbs. 100 in.lbs.
der rod, cycle the cylinder a minimum of 5 times with (271 Nm) (12 Nm)
the bleeder port unplugged venting all trapped air to
atmosphere. A suitable hose may be attached to the Slave Cylinder 200 ft.lbs. 100 in.lbs.
bleeder port with the end in a container suitable to (271 Nm) (12 Nm)
contain the hydraulic fluid. After all air is vented
remove all attached hoses, and install the bleeder
NOTE: After torquing piston nut spot drill cylinder rod for
port plug. Also plug the extend and retract ports until
setscrews.
cylinder is installed in boom.
Table 5-2.Holding Valve Torque Specification 11. Remove the two (2) extension chain adjusting nuts
from the eyebolt through the chain adjust assembly.
Description Torque Value
12. Remove the four (4) bolts and lock washers attach-
SUN - 7/8 HEX M20 x 1.5 THDS. 30-35 ft.lbs. ing the chain attach block to the base boom section
(41-48 Nm) and remove the block.
45-50 ft.lbs. 13. Using the lifting equipment, raise the telescope cyl-
SUN - 1 1/8 HEX 1-14 UNS THDS.
(61-68 Nm) inder enough to obtain adequate clearance for
150-160 ft.lbs. removal of the telescope cylinder rod support
SUN - 1 1/4 HEX M36 x 2 THDS. bracket.
(204-217 Nm)
50-55 ft.lbs. 14. Remove the cylinder rod support bracket.
RACINE - 1 1/8 HEX 1 1/16-12 THDS.
(68-75 Nm) 15. Attach a suitable lifting device to the extension chain
75-80 ft.lbs. adjusting eyebolt above the cylinder rod.
RACINE - 1 3/8 HEX 1 3/16-12 THDS.
(102-109 Nm) NOTE: The extension chain will come out of the boom twice
100-110 ft.lbs. as far as the telescope cylinder.
RACINE - 1 7/8 HEX 1 5/8-12 THDS.
(136-149 Nm)
16. Using both lifting devices, carefully pull the cylinder
from the boom assembly.
5.5 CYLINDER REMOVAL AND 17. As the cylinder is removed from the boom, lay the
extension chain on top of the base boom.
INSTALLATION
18. Using another lifting device, support the sheave
Telescope Cylinder Removal wheel end of the cylinder and remove the cylinder
from the boom assembly.
1. Be sure the boom is fully retracted and in a horizon- 19. Carefully lift the cylinder clear of the boom assembly
tal position. and lower to the ground or suitably supported work
2. Shut down the engine. Support the boom basket area.
end with a prop. (See Figure 5-2.)
Telescope Cylinder Installation
3. Remove the boom end-cover.
1. Using suitable lifting equipment, carefully lower the
cylinder to the boom assembly.
HYDRAULIC LINES AND PORTS SHOULD BE CAPPED IMMEDI- 2. Using another lifting device, support the sheave
ATELY AFTER DISCONNECTING LINES TO AVOID THE ENTRY OF wheel, or rod end, of the cylinder and install the cyl-
CONTAMINANTS INTO THE SYSTEM. inder into the boom assembly.
3. Slide the cylinder into boom, sliding the extension
4. Tag and disconnect the hydraulic lines to the tele-
chain in place as the cylinder is moving in.
scope cylinder. Use a suitable container to catch any
residual hydraulic fluid. Cap all hydraulic lines and 4. Attach a suitable lifting device to the extension chain
ports. adjusting eyebolt.
5. Remove the two snap rings that retain the telescope 5. Attach the cylinder rod support bracket to the rod
cylinder pin to the base boom. support block on the telescope cylinder.
6. Using a suitable brass drift, carefully drive the tele- 6. Install the chain adjust block with four (4) lock-
scope cylinder pin from the base boom. washer and bolts to the base boom section.
7. Remove the telescope cylinder trunnion pin covers 7. Install the two (2) extension chain adjusting nuts that
from each side of the base boom. attach the eyebolt to the chain adjust block.
8. Remove the capscrews securing the trunnion pins 8. Remove the lifting device from the telescope cylin-
from each side of the boom. der.
9. Using a suitable slide hammer, remove the trunnion 9. Using a suitable brass drift install the trunnion pins
pins attaching the telescope cylinder to the mid attaching the telescope cylinder to the mid boom
boom. section.
10. Attach a suitable sling to the telescope cylinder. 10. Install the capscrews securing the trunnion pins to
Support the cylinder with an overhead crane or each side of the boom. Note that loctite 242 is
other suitable lifting device. required on the capscrew threads.
11. Install the trunnion pin covers on each side of boom. 4. Using auxiliary power, extend the cylinder rod until
12. Carefully install the telescope cylinder barrel attach the attach pin hole aligns with those in the boom.
pin into the base boom. Using a suitable drift, drive the cylinder rod attach
pin through the aligned holes, taking care to align
13. Install the snap rings that retain the telescope cylin- the grooved pin holes. Secure the pin in place with
der pin to the base boom. attaching hardware.
14. Remove applicable hydraulic line and port caps and 5. Remove the boom prop and overhead crane. Acti-
correctly connect the hydraulic lines to the tele- vate the hydraulic system.
scope cylinder. Ensure all hoses are correctly
routed. 6. Using all applicable safety precautions, operate the
boom functions. Check for correct operation and
15. Install the boom end cover. hydraulic leaks. Secure as necessary.
16. Activate hydraulic system. 7. Check the fluid level of the hydraulic tank and adjust
17. Using all applicable safety precautions, operate the as necessary.
boom functions. Check for correct operation and
hydraulic leaks. Secure as necessary.
18. Cycle (extend/retract) boom several times, then 5.6 TELESCOPE CYLINDER ECCENTRIC
torque boom chains to 40 ft. lbs. (2.76 Bar). See BUSHING
Boom Chains in Section 4, Boom & Platform for cor-
rect torquing procedure. IMPORTANT
19. Check fluid level of hydraulic tank and adjust as nec- RELOCATE ALTERNATE SETSCREW HOLE ONLY WHEN REPLAC-
essary. ING ECCENTRIC BUSHING.
When replacing the eccentric bushings, drill 5/16" dia. x 3/
Boom Lift Cylinder Removal 4" deep, tap 3/8-16NC x 9/16" deep for a new setscrew
(bushing to boom) either above or below original holes.
1. Place the machine on a flat and level surface. Start Allow enough room between the holes for strength while
the engine and place the boom in a horizontal posi- staying on the thick side of the bushing. (See Figure 5-10.)
tion. Shut down the engine and prop the boom. (See
Figure 5-2.)
2. Remove the hardware retaining the cylinder rod
attach pin to the boom. Using a suitable brass drift,
drive out the cylinder rod attach pin.
3. Using auxiliary power, retract the lift cylinder rod
completely.
4. Disconnect, cap and tag the boom lift cylinder
hydraulic lines and ports.
5. Remove barrel end attach pin retaining hardware.
Using a suitable brass drift drive out the barrel end
attach pin from the turntable upright.
6. Remove the cylinder from the boom and place in a
suitable work area.
Boom Lift Cylinder Installation Figure 5-10. Telescope Cylinder Eccentric Bushing
Figure 5-11. Racine Proportional Air Gap Adjustment, Machines Built Prior to Mid 1987
1. With all parts assembled as shown in Figure 5-11., 4. Pressure And Flow Settings Machines Built Prior To
use a depth mike or other measuring instrument to May 1992 With Steering Wheel are shown in Figure
determine the distance from the end of the guide 5-19.
tube to the exposed end of the plunger. Record this 5. Vickers Proportional Valve Pressure Setting,
dimension. Machines Built To Present are shown in Figure 5-20.,
2. Remove the plunger and poppet. With the poppet Figure 5-21., Figure 5-22., and Figure 5-23.
removed, install the plunger and check the distance
6. Vickers All Hydraulic Pressure Setting are shown in
from the end of the guide tube to the exposed end of
Figure 5-24., Figure 5-25., Figure 5-26., and Figure
the plunger.
5-27.
3. Subtract the first dimension from the second dimen-
sion, this will be the amount of air gap. 7. Solenoid Valve Pressure Settings Machines Built To
Present are shown in Figure 5-28.
4. The correct air gap is 0.018"- 0.020" with 0.018" pre-
ferred. If the air gap is excessive, it may be reduced 8. Solenoid Valve Pressure Settings 4 W/S are shown
by using a brass drift and hammer. Lightly tap the in Figure 5-29.
end of the plunger with all parts assembled. 9. Extend - A - Reach Valve Pressure and Speed Set-
Recheck the air gap. tings are shown in Figure 5-30.
Figure 5-12. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 1 of 2)
Figure 5-13. Racine Proportional Valve Pressure Setting - Prior to Mid 1987 (Sheet 2 of 2)
Figure 5-14. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 1 of 4)
Figure 5-15. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 2 of 4)
Figure 5-16. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 3 of 4)
Figure 5-17. Vickers Proportional Valve Pressure Setting - Prior to 1989 with Accessory Valve (Sheet 4 of 4)
Figure 5-18. Solenoid Valve Pressure Settings - Prior to Mid 1992 with Steering Wheel
Figure 5-19. Pressure and Flow Settings - Machines Prior to Mid 1992 with Steering Wheel
Figure 5-20. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 1 of 4)
Figure 5-21. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 2 of 4)
Figure 5-22. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 3 of 4)
Figure 5-23. Vickers Proportional Valve Pressure Setting - Mid 1992 to Present (Sheet 4 of 4)
Restricted or broken hydraulic line or fitting on Clean, repair, or replace line or fitting.
slave cylinder or main lift cylinder.
Slave level or main lift cylinder not functioning Slave level or main lift cylinder not functioning
properly. properly.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
CONTROL VALVES
Dirt in oil causing excessive temperature build- Flush system and change oil using recom-
up. mended viscosity
Incorrect valve mounting causing warping of the Loosen valve and check mounting. Repair as
unit. necessary.
Return spring weak or broken. Remove valve and repair or replace as neces-
sary.
Relief valve malfunctioning causing excessive Check pressure delivery to and from valve and
pressure within valve. repair or replace as necessary.
Valve leaking.
Dirt or other foreign material under seal. Remove and repair valve as necessary.
Excessive back pressure caused by restricted Remove line and clear obstruction or replace line
return line to reservoir. as necessary.
Dump valve (bypass) not operating. Determine cause and repair or replace valve.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Binding lift cylinder or boom pivot pin. Repair or replace cylinder or pin.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Pump Volume, Wheel Motor Speed and High Engine does not operate below horizontal.
TELESCOPE SYSTEM.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Swing control switch not functioning. Repair or replace swing control switch.
Foreign objects(s) wedged between swing Remove objects, check for damage, and repair
motor pinion and swing gear. or replace component(s) as required.
Pressure reducing valve in swing circuit malfunc- Repair or replace pressure reducing valve.
tioning.
Restricted or broken hydraulic line or fitting. Clean, repair, or replace line or fitting.
Foreign object(s) wedged between swing motor Remove object(s), check for damage and repair
pinion and swing gear. or replace component(s) as required.
Swing control switch not functioning properly. Repair or replace swing control switch.
Lack of lubricant on swing gear or speed reducer Lubricate as required. (See Lubrication Chart.)
pinion.
Swing motor not functioning properly. Repair or replace swing control switch.
CONTROL VALVE.
Dirt in oil causing excessive temperature built- Change oil using recommended viscosity and
up. flush system.
Incorrect valve mounting causing warping of the Loosen valve and check mounting.Repair as
unit. necessary.
Return spring weak or broken. Remove valve and repair or replace as neces-
sary.
Relief valve malfunctioning causing excessive Check pressure delivery to and from valve and
pressure within valve. repair or replace as necessary.
Valve leaking.
Dirt or other foreign material under seal. Remove and replace valve as necessary.
Excessive back pressure caused by restricted Remove line and clear obstruction or replace line
return line to reservoir. as necessary.
POWER PLANT.
Fuel shut-off valve in carburetor stuck or frozen. Repair or replace fuel shut-off. Check for electri-
cal power.
Cam timing belt jumped time or broken. Repair or replace timing belt.
Engine surges.
Fuel tank overfilled. Check fuel tank and immediately wipe up spilled
fuel.
Fuel tank damaged. Drain all fuel from tank and remove tank for
replacement or repair.
Steering link or tie rod broken or attaching hard- Replace steering link, tie rod or hardware as nec-
ware missing. essary.
Wheel hub or bearings damaged or not lubri- Replace hub or bearings as necessary and
cated. repack bearings with approved grease.
Machine being moved up too steep a grade. Remove machine from grade and check that
drive system operates correctly.
Drive wheel tire treads worn smooth. Replace tires as necessary and inflate to speci-
fied pressure.
DRIVE SYSTEM.
No response to control.
Air in wheel brake circuit. Bleed circuit, determine and correct cause.
Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting.
Counterbalance valve sticking on return side. Adjust return counterbalance out 3 turns - cycle
drive - return to original position.
Sticking spool due to contamination. Remove end cap and check spool freedom.
Repair as necessary.
Valve spool is not traveling far enough due to: Repair or replace drive motor(s).
Low spool spring preload. Check for correct spring and shims in end caps.
Sticking spool due to contamination. Remove end cap and check spool freedom.
STEERING SYSTEM.
Steering inoperative.
Relief valve improperly set or not functioning Reset, repair or replace valves as required.
properly.
No oil flow or pressure to steer circuit. Take pressure reading at steer valve and adjust
as necessary.
Crossover relief valve set too low or not function- Reset, repair or replace valve as required.
ing properly.
Steer wheel toe-in not set properly. Adjust toe-in for 1/4 inch overall.
Air entering system through broken line or fitting. Repair or replace line or fitting.
(Suction Side.)
Air bubbles in oil. (Reservoir oil too low. Replenish oil as required.
Oil viscosity too high. Drain system and replace with recommended oil.
(Refer to Hydraulic Oils.)
System overheating.
Oil viscosity too high. Drain system and replace with recommended oil.
(Refer to Hydraulic Oils.)
Air entering system through broken line or fitting. Repair or replace line or fitting.
Pump section not delivering sufficient oil. Repair or replace pump section or pump.
Main relief valve stuck in open position. Clean, repair, or replace valve. (Check system oil
for contamination.)
Oil viscosity too low. Drain system and replace with recommended oil.
(Refer to Hydraulic Oils.)
Battery requires charging or will not hold a Charge or replace battery as required.
charge.
Restricted or broken hydraulic line or fitting. Clean, repair or replace line or fitting.
PLATFORM CONTROLS.
15 Amp self-reset circuit breaker open. Check footswitch to ensure that both switches
are making contact when pedal is depressed.
Repair or replace footswitch as necessary.
Faulty power circuit wiring. Check wiring continuity. Refer to proper wiring
diagram.
Discharged battery or loose battery terminals. Check and charge battery or replace battery as
necessary. Clean and secure battery terminals.
Starter relay faulty or faulty relay connections. Using a test meter, check relay coil terminals for
presence of electrical power and for energization
of relay coil. Also check relay terminals for cor-
rect switching of contacts. Replace relay as nec-
essary.
Malfunctioning ignition switch. Using a test meter, check ignition switch for cor-
rect switching of contacts. Replace switch as
necessary.
Faulty ignition and/or starter circuit wiring. Check wiring continuity. See proper wiring dia-
gram.
Faulty ignition and/or starter circuit wiring. Check wiring continuity. See proper wiring dia-
gram.
Hourmeter inoperative.
Damaged wiring in tilt alarm circuit. Repair or replace wiring. See proper wiring dia-
gram.
4932813-
Figure 6-1. Wiring Schematic Dual Fuel
4931693 E
Figure 6-2. Wiring Diagram - Generator (Deutz Engines)
4932806 B
Figure 6-3. Wiring Diagram - Generator (Ford Engine)
1281682-B
Figure 6-5. Wiring Diagram - Platform Console Standard Controls (Sheet 2 of 2)
4932027D
Figure 6-6. Wiring Diagram - Platform Console Hydraulic Controls
Figure 6-7. Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls) (Sheet 1 of 2)
1280750 G
Figure 6-8. Wiring Diagram - Standard (Deutz Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2)
4932833 E
Figure 6-10. Wiring Diagram - Standard (Deutz Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2)
1280992 F
Figure 6-12. Wiring Diagram - Standard (Deutz Engine/Hydraulic Controls)(Sheet 2 of 2)
1282458 C
Figure 6-14. Wiring Diagram - Standard (Ford Engine/Fixed Axle/Standard Controls)(Sheet 2 of 2)
4932834 E
Figure 6-16. Wiring Diagram - Standard (Ford Engine/Oscillating Axle/Standard Controls)(Sheet 2 of 2)
1282616-
Figure 6-18. Wiring Diagram - Standard (Ford Engine/Hydraulic Controls)(Sheet 2 of 2)
2792231-
Figure 6-20. Hydraulic Schematic (Sheet 2 of 6)
2792231-
Figure 6-22. Hydraulic Schematic (Sheet 4 of 6)
2792231-
Figure 6-24. Hydraulic Schematic (Sheet 6 of 6)
JLG Latino Americana Ltda. JLG Europe B.V. JLG Industries (Norge AS) JLG Polska
Rua Eng. Carlos Stevenson, Jupiterstraat 234 Sofeimyrveien 12 UI. Krolewska
80-Suite 71 2132 HJ Foofddorp N-1412 Sofienyr 00-060 Warsawa
13092-310 Campinas-SP The Netherlands Norway Poland
Brazil Phone: (31) 23 565 5665 Phone: (47) 6682 2000 Phone: (48) 91 4320 245
Phone: (55) 19 3295 0407 Fax: (31) 23 557 2493 Fax: (47) 6682 2001 Fax: (48) 91 4358 200
Fax: (55) 19 3295 1025
JLG Industries (Europe) JLG Industries (Pty) Ltd. Plataformas Elevadoras JLG Industries (Sweden)
Kilmartin Place, Unit 1, 24 Industrial Complex JLG Iberica, S.L. Enkopingsvagen 150
Tannochside Park Herman Street Trapadella, 2 Box 704
Uddingston G71 5PH Meadowdale P.I. Castellbisbal Sur SE - 175 27 Jarfalla
Scotland Germiston 08755Castellbisbal Sweden
Phone: (44) 1 698 811005 South Africa Spain Phone: (46) 8 506 59500
Fax: (44) 1 698 811055 Phone: (27) 11 453 1334 Phone: (34) 93 77 24700 Fax: (46) 8 506 59534
Fax: (27) 11 453 1342 Fax: (34) 93 77 11762